Winding assembly for an electric generator and motor rotor and method of maintaining position of a winding assembly

Abstract

A winding assembly for an electric generator includes a stator core having a relatively cylindrical inner shape. Also included is a rotor core coaxially rotatable within the stator core, wherein the rotor core includes an input shaft. Further included is a rotor winding support structure on the rotor core and comprising a surface disposed at an angle relative to the input shaft and extending radially outward from the input shaft toward the stator core. Yet further included is a rotor winding bundle disposed along, and supported by, the surface of the rotor winding support structure.

The invention claimed is: 
     
       1. A winding assembly for an electric generator comprising:
 a stator core having a relatively cylindrical inner shape; 
 a rotor core coaxially rotatable within the stator core, wherein the rotor core includes an input shaft; 
 a rotor winding support structure on the rotor core and comprising a radially inner surface, a radially outer surface and a surface extending between the radially inner surface and the radially outer surface, the surface extending radially outward from the input shaft toward the stator core, the entire length of the surface disposed at an angle that is non-perpendicular and non-parallel to an axis of rotation of the rotor core; and 
 a rotor winding bundle disposed along, and supported by, the surface of the rotor winding support structure, wherein the angle relative to the input shaft is less than 90 degrees as the surface extends radially outwardly to form an incline of resistance for the rotor winding bundle, the incline of resistance extending along an entire length of the surface extending between the radially inner surface and the radially outer surface. 
 
     
     
       2. The winding assembly of  claim 1 , wherein the rotor winding bundle comprises a plurality of cables. 
     
     
       3. The winding assembly of  claim 2 , wherein the plurality of cables comprises a plurality of magnet wires. 
     
     
       4. The winding assembly of  claim 1 , further comprising a plurality of rotor winding support structures circumferentially spaced from each other to form at least one slot opening. 
     
     
       5. The winding assembly of  claim 4 , wherein the rotor winding bundle is disposed within the at least one slot opening. 
     
     
       6. The winding assembly of  claim 5 , wherein the at least one slot opening extends between the input shaft and an outer diameter of the rotor core. 
     
     
       7. A method of maintaining positioning of a winding assembly comprising:
 forming a rotor winding bundle with a plurality of rotor winding cables; and 
 disposing the rotor winding bundle along a surface of a rotor winding support structure, wherein the surface extends radially between a radially inner surface and a radially outer surface, the entire length of the surface arranged at an angle that is non-perpendicular and non-parallel to an axis of rotation of the rotor core, wherein the surface extends radially from the input shaft towards a stator core surrounding the rotor core in operation, wherein the angle relative to the input shaft is less than 90 degrees as the surface extends radially outwardly to form an incline of resistance for the rotor winding bundle, the incline of resistance extending along an entire length of the surface extending between the radially inner surface and the radially outer surface. 
 
     
     
       8. The method of  claim 7 , wherein the plurality of cables comprises a plurality of magnet wires. 
     
     
       9. The method of  claim 7 , wherein the surface is integrally formed with a first rotor winding support structure circumferentially spaced from a second rotor winding support structure to form at least one slot opening. 
     
     
       10. The method of  claim 9 , wherein the rotor winding bundle is disposed within the at least one slot opening. 
     
     
       11. The method of  claim 10 , wherein the at least one slot opening extends between the input shaft and an outer diameter of the rotor core. 
     
     
       12. The method of  claim 9 , wherein the first rotor winding support structure is angled relative to the input shaft in an opposite direction from the second rotor winding support structure.